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Minimum quantity lubrication – Industry 4.0

Minimum quantity lubrication – Industry 4.0

by | May 29, 2021 | Expertise

Minimum quantity lubrication (MQL) – ready for Industry 4.0 Oil quantity, volume flow and pressure of the MQL aerosol can be directly taken into account in the digital process chain. This offers a clear advantage in comparison to conventional metalworking fluids. Figure 1: Good spraying behavior Effective delivery of metalworking fluids Metalworking fluids, minimum quantity lubrication and cryogenic components are complex issues. Regardless of the method, the basic objectives of the cutting industry are high process reliability and high productivity. In addition to the economic ideas, ecological aspects are playing an increasingly important role. When things work out well, they can, in turn, also offer potential savings in energy and other resources. All metalworking fluid-related lubrication methods, including MQL, have a common characteristic: continuous targeted feeding of the metalworking fluid into the cutting zone. The metalworking fluid must be delivered accurately onto the rake and flank face of the cutting tool. This can best be achieved by means of an internal metalworking fluid supply. Processes and advantages with Minimum Quantity Lubrication (MQL) The MQL process creates an aerosol comprised of an oil-air mixture. This mixture forms a protective film, which reduces the friction and directly prevents the tool’s wear. Cooling of the cutting tool is achieved / controlled by means of forced convection via compressed air, wet surfaces and evaporation enthalpy. Processes such as high-speed cutting (HSC) or high-feed cutting (HFC) are fundamental prerequisites for cutting successfully with MQL. In this case, an MQL-optimized cutting process requires smaller, constant wrap angles in order to reduce the total heat input into the tool. In recent years, there has been a significant development both in the field of MQL devices, delivery systems and the cutting tools themselves. Compared to wet machining, MQL is a more flexible application, since smaller amounts of fluid are fed. However, due to this reduction of fluid, it is imperative to pay close attention to the continuous and targeted feeding of the cutting tool with the MQL aerosol. The low energy consumption, the cleanliness of the parts and chips, as well as good material compatibility are further advantages of this method.   MQL and Industry 4.0 The integration of MQL and modern MQL systems in the digital process chain can be realized more easily and quickly than with conventional...
Research on the processing of turbine blades with minimum quantity lubrication

Research on the processing of turbine blades with minimum quantity lubrication

by | May 29, 2021 | Expertise

Research on the processing of turbine blades with minimum quantity lubrication Demo blades at Liechti Engineering on a Turbomill 1400i (turnaround time: 63min). The mass of the blank amount to: 150x70x480mm. Blaser Swisslube has carried out an extensive analysis of the milling of steel turbine blades in collaboration with GF Machining Solutions AG – Liechti Engineering and Walter AG. Conclusion: Minimum quantity lubrication (MQL) makes it possible to optimise the process and offers a savings potential when it comes to tool costs. The collaborative effort began about 1.5 years ago. Liechti Engineering initiated the project, intending to optimize the processing of turbine blades with the support of Blaser Swisslube and Walter. The blades, made of high-alloyed heat-resistant steel, are first roughened, and then pre- finished before a final finishing. The key processing phase in particular (meaning: the longest cycle time, and thus the highest production costs) was carefully examined throughout the course of the project. Blaser Swisslube’s Technology Centre During the initial tests at Blaser Swisslube’s in-house technology centre at the headquarters in Hasle-Rüegsau, X20 chrome steel blocks were milled using a GF Mikron HPM 800U – both rough-ing and finishing. The processing was carried out using a metalworking fluid, MQL, as well as dry and with pure compressed air cooling, and subsequently compared. Various cutting parameters were used. The MQL processing demonstrated its merits when it came to reduced flank wear during finishing, and the surface finish was very good as well. It therefore proved to be the ideal choice for this process. Technology Center and Competence Center of Blaser Swisslube in Hasle-Rüegsau Research results obtained by Liechti Engineering Further tests were then carried out at Liechti Engineering in Langnau. Blades were machined using a Turbomill 1400i. The results obtained match the findings made at Blaser’s technology centre. Apart from X20 chrome steel, Liechti Engineering also processed hard-to-machine X2 chrome steel in order to put the MQL process under scrutiny. Conclusion: Thanks to the MQL processing, the wear on the cutting edge is reduced and the tools have a longer life. This offers a savings potential with regards to the tool costs. Test showed that when finishing with MQL, tool wear can be reduced by a factor of up to 5 compared to metalworking fluid Result of the collaboration “MQL processing is the perfect choice for...
Steadily expanding our expertise in the field of minimum quantity lubrication

Steadily expanding our expertise in the field of minimum quantity lubrication

by | May 29, 2021 | Expertise

Steadily expanding our expertise in the field of minimum quantity lubrication The GROB G550 converted to MMS at the Blaser Swisslube Technology Center For this purpose, Blaser invested in a new GROB machine and converted it to minimum quantity lubrication (MQL). A holistic approach that takes into consideration all parameters involved in the process is typical. That is why Blaser also works with different partners, for example EMUGE. A metalworking fluid manufacturer interested in (or using) MQL—isn’t that a contradiction? For Blaser Swisslube, metalworking fluid and minimum quantity lubrication go hand in hand. What may sound a little strange to some, is normal for the Swiss family business. “We are committed to providing our customers with measurable added value in the field of cutting and grinding fluid and lubricant solutions. Whether it’s with a suitable cutting and grinding fluid or with a minimum quantity lubricant matched to the process,” explains Marc Blaser, CEO of Blaser Swisslube. In order to expand expertise in the field of MQL, a GROB G550 machine was purchased this year, which was specifically modified for MQL production. “We are looking to develop steadily, and better understand the fields of activity in MQL. To this end, we work closely with partners,” he concludes. Thread forming at the GROB with tools from EMUGE Competence in minimum quantity lubrication When using MQL, the entire process has to be taken into consideration. Significant progress has been made in the field of MQL over recent years, which also presents metalworking fluid manufacturers with the challenge of developing products specially suited for this purpose. Given the appropriate machining processes and the right implementation, Blaser Swisslube sees huge potential in MQL. Conversion to MQL requires adaptation of tools and process parameters. However, many users lack experience with MQL processes, which can be compensated for by the involvement of experts and the knowledge of tool, equipment and metalworking fluid suppliers. “With the machine converted to MQL, Blaser Swisslube can compare applications and materials with MQL, cutting and grinding oils and water-miscible coolants, and build up practical process knowledge. We want to provide answers to our customers’ questions – including in the field of MQL,” says Tobias Mathys, Process Engineering Manager at Blaser Swisslube. Process development with EMUGE A project with...
Cutting and grinding fluid tests – how we test in the Technology Center

Cutting and grinding fluid tests – how we test in the Technology Center

by | May 29, 2021 | Education

Cutting and grinding fluid tests – how we test in the Technology Center The Research and Development laboratory at Blaser Swisslube At Blaser Swisslube, we have been testing our cutting and grinding fluids in our in-house Technology Center using the latest generation of CNC machines since 2009. There are many factors to consider in these experiments. The most important thing, however, is a clean and very precise approach. A good cutting and grinding fluid has many features. In my series, I’m going to explain what needs to be considered when performing tests on cooling and grinding fluids. In the first part, I’m going to talk about materials and tools. A good cutting and grinding fluid has many features. In my series, I’m going to explain what needs to be considered when performing tests on cooling and grinding fluids. In the first part, I’m going to talk about materials and tools. Several departments work together when a new cutting and grinding fluid is developed. On the one hand, there is our Product Management team, which assesses market requirements and orders new products for development on this basis. On the other hand, there is our Research and Development laboratory. Here our chemists work tirelessly on increasingly powerful, stable and compatible products. Last, but not least, we are pleased when we receive practical feedback and suggestions from our Customer Service, which we then use in further development. Cutting and grinding fluid tests – evaluation of strengths and weaknesses Of course, all chemical and biological features, as well as human and environmental compatibility, are recorded in the laboratory. The data already covers a very wide range of information. Performance in different materials can be estimated effectively using the tribological parameters. However, the tests in our Technology Center are vital in order to assess effective performance in practical machining applications. But what does performance mean in relation to a cutting and grinding fluid? One of the most important features is the influence on tool life with consistent parameters. In order to reliably determine this influence, we need to call on our extensive experience, our modern infrastructure and our ability to work with ultimate precision. The only factor that can change from test to test is the cutting and grinding fluid. In order to get closer to the customer and everyday practice, we have had our own Technology Center since 2009 where I’m...
An enthusiastic Blaser user – BOOM!

An enthusiastic Blaser user – BOOM!

by | May 29, 2021 | Education

An enthusiastic Blaser user – BOOM! Titan is a big Blaser fan Titan Gilroy is an enthusiastic Blaser user and owner of TITANS of CNC. He only uses the best metalworking fluids available on the market. Titan is a fighter, and with his online platform, TITANS of CNC Academy, he has given many people an understanding of machining technologies while sharing his knowledge. Titan Gilroy is the personification of the American Dream, having made it to the very top through his own hard work. A former boxer, he is now the owner of TITANS of CNC, a CNC manufacturing workshop in Northern California, US. He also produces and stars in the TV series by the same name, TITANS of CNC, (formerly: TITAN American Built). He has founded his online platform, TITANS of CNC Academy, to offer free training for those interested in machining, students and many more in the field of CAD, CAM and CNC. Titan designed the curriculum used by the trainers and students. The online portal is the first training platform of its kind and now has fans and visitors from all over the world. It all began with the CNC machining school in the San Quentin prison. The Titan knows first-hand that the American prison system could be doing a much better job. Many former inmates stated they found it difficult to resume their life in society and to find work. In order to offer the prisoners a new perspective and to train them, an entire workshop, including state-of-the-art equipment, was built based on his ideas. The concept was a complete success, as you can see in the video below. Collaboration with Blaser Swisslube Titan has made it his mission to promote training in the machining industry in the United States. Titans of CNC and Blaser Swisslube have been working together for almost two years now. In addition to sponsors like Autodesk, Haas and Kennametal, Blaser supports the Titans of CNC Academy’s free learning platform. Furthermore, Titan is one of our metalworking fluid test users – a symbiotic collaboration. In January 2016, the time had come for Titan and his crew to pay us a visit. See the film about Titans’ 2022 visit at Blaser Swisslube, Switzerland here. Titans of CNC Academy – The Free Training Platform You can find a number of different learning modules in the fields of programming, tool optimization and metalworking fluid handling on the Academy website. The purpose of the platform is to enable interested parties to develop and learn new things. His followers include both...
What happens with the metalworking fluid samples?

What happens with the metalworking fluid samples?

by | May 28, 2021 | Education

What happens with the metalworking fluid samples? The journey of the metalworking fluid samples through the laboratory Triage for customer samples Our customers from all over the world send metalworking fluid samples to Hasle Rüegsau in Switzerland. Hundreds of customer samples found their way to our laboratory last year, where they were analyzed in detail by our specialists. Almost 7,000 of these samples were sent to the microbiologists in our customer service team. What happens with a customer sample? What is involved in standard analysis and what is the difference between a dip slide and a plater? Triage for customer metalworking fluid analysis In the early morning, all the metalworking fluid samples that have arrived from customers all over the world are lined up on the laboratory bench in customer service. Each sample is delivered together with a sampling report. This records the customer name, products used, tank size, filling date and much more. Measurements showing the concentration and the local pH value are also included. Each of these customer samples is now assigned a unique internal number and all the data collected are recorded electronically. The samples that have arrived for standard analysis include the following two used emulsions, which I will now deal with in a little more detail: Customer sample 1 Customer sample no. 1 / Customer sample from Germany A German customer uses our B-Cool metalworking fluid. The pH value and the concentration have already been measured on site and our sales representative sent a sample from the 6,000 liter sump to Switzerland for further analysis. Customer sample no. 2 / Customer sample from Switzerland A Swiss customer has been using a Blasocut metalworking fluid for several years. In order to check the condition of the emulsion, a sample of the used emulsion was taken from the customer’s central system. Because of their different product properties, the two customer samples now complete different test procedures. Customer sample 2 CustomerYeast, mold and bacteria cultivated on nutrient agar Customer sample no. 1 – Analysis of conserved products: Microbial growth is not usually tolerated in traditional products because the ingredients suppress the growth of microorganisms in the ready-to-use product. In order to check that everything is in order with the metalworking fluid, we use the so-called dip slide for analysis. The dip slide is coated on both sides with a nutrient agar. If bacteria, yeast and/or...